X-Ray & CT Scanning Archives - Industrial Inspection & Consulting

X-Ray & CT Imaging of Endoscopy Medical Device

X-Ray CT Inspection of Pillcam

Pill cameras, or “pillcams,” are small, ingestible devices used to capture images of the inside of the gastrointestinal tract. They are particularly useful for diagnosing conditions like Crohn’s disease, ulcers, and cancers in areas that are hard to reach with traditional endoscopy, such as the small intestine. The main benefit of pillcams is that they offer a minimally invasive, comfortable alternative to more traditional procedures, allowing doctors to observe the GI tract in real time as the pill moves through the system.

Industrial CT scans can assess the alignment and assembly of small, complex parts inside medical devices like pillcams, ensuring that all components are correctly positioned and functioning as intended. This technology offers high-resolution 3D imaging, allowing for precise analysis of intricate details that would be difficult to detect with traditional inspection methods like X-ray or visual inspection. Thus, CT scanning plays a critical role in ensuring that medical devices meet safety, performance, and quality standards before being released for use.

Battery evaluation for alignments, connections, and spring contact
Micro-PCB showing solder joint porosity

Diagnosing Failure Within a CubeSat Using Industrial X-Ray & CT Scanning

DIAGNOSING FAILURE WITHIN A CUBESAT

Industrial Inspection played a critical role in diagnosing a failure within this CubeSat. Set to launch on a SpaceX rideshare in November 2024, our client walked into our lab with a defective, seven-figure satellite and walked out with a plan for repair. We were challenged to determine the defect within one day so that build technicians would have enough time to tear down and repair or replace necessary components. Armed with only suggestions of possible zones for failure, our certified experts took on the challenge of finding this needle in a haystack.

“Our staff is comprised of world class inspection experts hailing from renowned inspection labs, space companies, and defense contractors. We thrive under pressure and perform at our best when failure is not an option,” said Keith Irwin, Managing Partner of Industrial Inspection.

THE CHALLENGE

Large, complex systems like this CubeSat present a variety of challenges for Industrial X-Ray Imaging & CT Scanning. For example, opposing parameters like resolution versus energy must be weighed for their pros and cons. Without enough energy there would be a lack of penetration and increased x-ray artifacts. But, higher energy also introduces a larger x-ray spot-size and reduced resolution.

When imaging PCBs and searching for cracks or foreign object debris, resolution reigns supreme. Because of this, we swapped our 320kv mesofocus x-ray source (>30um resolution) out for our 225kv microfocus source (>3um resolution) in our large format x-ray cabinet. In order to locate any potential defects we must work through increased noise and artifacts to find miniscule defects.

Below is the point of failure – the signal amplifier likely overheated causing fracture. The left image shows a cross-sectional view through the side of the component, the middle view shows a top-down cross-section, and the right view shows the 3D render with the location of the component.

REACTION WHEEL IMAGING

Other areas of the satellite were also imaged for general information purpose like this reaction wheel and its copper windings.

Powered by batteries energized by small solar panels, reaction wheels are the preferred method for attitude control and stabilization. When a wheel spins, it creates angular momentum in one direction, causing the spacecraft to rotate in the opposite direction. By changing the speed of the wheels, the satellite can control its orientation in space without using propellant. This is particularly useful for precise pointing of instrumentation without the need for propellant.

All information has been shared with permission by our client.

CT Scanning Tensile Strips

Tensile strips are manufactured materials used to measure or apply tensile stress in various applications. They are often used in structural engineering and material testing to evaluate the strength and elasticity of materials under tension. They come in a variety of shapes, sizes, and materials.

However, the sample in this case study is for a different purpose. While some manufacturers look to eliminate as much porosity as possible, others attempt to create a distribution of porosity for reasons like: flexibility, sound absorption, thermal insulation, and product lightening.

Industrial CT Scanning is used to characterize, quantify, and create 3D representations of these strips for failure analysis and FEA. Data can be exported into a variety of file formats.

100gb High Resolution Helical Scan of Tensile Strip

1000% ZOOM ON DATA - POROSITY & RESIN ORIENTATION WITNESSED

HIGH DENSITY INCLUSIONS EXTRACTED AND MAPPED

POROSITY CAN BE SEGMENTATED AND CALCULATED FOR TOTAL OR INDIVIDUAL PORE VOLUME

IIC files PPA for CT Obfuscation Invention

World’s First Collector Card CT Scanning Service

UPDATE 8/3/2024:
We are aware of and working through the moral dilemma of CT scanning sealed collectibles. Our objective position is one of scientific ability and data-driven results. It is not our responsibility to determine the ethical positions and choices of others and we do not accept responsibility for their actions.
1. We have brought awareness to the entire industry of the existence and capabilities of this technology; it is up to individuals to make informed decisions moving forward.
2. In light of information we have received from industry insiders, we believe companies are using this technology in secret to take advantage of the collectibles market.
3. We are making this technology accessible to everyone rather than to just a minority.
4. We are working on policies to combat deceptive practices.
5. We are working on partnering with manufacturers to develop packaging security solutions.
6. We will continue to consider every request we receive.
7. This technology is here to stay and there will probably be additional companies offering it as a service at some time in the future.
8. The majority of requests we have received have been from people curious about the value of their “30 year old collectible” and if this is their opportunity for a life changing moment.

INDUSTRIAL INSPECTION BECOMES THE WORLD'S FIRST COLLECTOR CARD CT SCANNING SERVICE

First, we made public what’s been happening in secret. Now, we are bringing x-ray vision to the masses – quickly, affordably, and reliably. Preserve your investments, maintain your edge against wealthy investors and bad actors, and understand the value of what you own. We can image everything from packs to booster boxes for sports and card games.

To learn more check out our Collector Card CT Scanning Page here:

COLLECTOR CARD CT SCANNING SERVICES

Inspecting Additively Manufactured Parts using Industrial CT Scanning

Inspecting Additively Manufactured Components using Industrial CT Scanning

Additive manufacturing (3D printing) allows for the creation of highly complex and intricate designs that would be difficult or impossible to achieve with traditional manufacturing methods. This includes features like internal channels, lattice structures, and custom geometries. Because these complex designs are typically internal, their inspection is also extremely difficult or impossible. One option is to physically cut the part, but this introduces a variety of consequences. Another option, and the purpose of this case study, is to digitally cut through the sample using Industrial CT Scanning technology. CT Scanning allows us to capture highly accurate data for the inspection of internal and external geometry of a variety of components.

ROTATIONAL VIEWING METHOD

Cylindrical parts like this can be viewed about an axis. A cylinder is defined and then the viewing pane rotates about that axis to show inconsistencies and indications. The left arrow shows vertical build failures. The right arrow shows trapped build material.

UNROLL VIEWING METHOD

For an alternative look at internal geometries, a cylindrical feature can be “unrolled” into a planar view. Image a toilet paper roll cut down one side and laid flat on a table. This offers the viewer the opportunity to simultaneously view a given offset from an axis.

VOLUMETRIC POROSITY CALCULATIONS

Porosity and inclusions can be extracted and calculated for volume, spherical diameter, and other characteristics. This information can be used to qualify parts or amend manufacturing parameters for better parts.

BUILD DEFECT LOCATING AND IMAGING

Internal build failures can be located and evaluated before the component makes it into the field.

CT Scanning Castings for Porosity

CT SCANNING CASTINGS FOR POROSITY EVALUATION

CT Scanning is used to quantify porosity within a part – whether it be plastics or metals. This information is useful for applications like process changes to reduce machining fallout or investigating failures like through wall leaks. As technology rapidly changes, large format, high energy CT systems paired with software packages like Volume Graphics can accommodate large and high density products.

Unlike 2D X-Ray imaging, 3D CT Scanning can volumetrically quantify porosity. This quantification can be exported to Excel for statistical analysis to comare between manufacturing changes.

This large air cooler required four scans for total data acquisition. We then aligned and contrast adjusted the CT scans for a seamless review of the casting.

First Article Inspections using PolyWorks

First Article Inspections

First Article Inspection (FAI) is a comprehensive verification process used in manufacturing to ensure that a newly produced part or component meets all specified requirements. It involves inspecting and testing the first production item against the engineering drawings, specifications, and other applicable standards.

FAI typically involves detailed inspections, measurements, and testing to verify critical dimensions, material properties, functionality, and performance characteristics of the part.

3D PROFILING

3D scanning is the process of creating a three-dimensional representation of an object. This representation is in the form of a scan file which can be compared to the perfect design model. The profile comparison heat map allows inspectors and manufacturers to identify defects, deviations, or areas of concern. The scale can be set to any tolerance:

Green to Red represents material “above” CAD surfaces

Green to Blue represents material “below” CAD surfaces

Gray represents geometry outside of the tolerance band

DIMENSIONAL INSPECTION

Dimensional inspection involves measuring various dimensions, such as distances, diameters, angles, complex GD&T like true positions, concentricity, and runout. These controls are used to ensure products conform to the design specifications and tolerances provided by engineering drawings.

We use PolyWorks Metrology Suite for programming, automated inspection, SPC evaluation, and imaging.

Industrial CT Step Scanning (4D CT) of Gaskets and Seals

Step Scanning FOR VARIOUS CONDITIONS

Step scanning, often referred to as “4D CT”, is the process of collecting several CT datasets at various product conditions, aligning those datasets to a common datum reference frame, and saving images to demonstrate product changes.

This practice is commonly used for parts or products that actuate or have several functioning positions. For example, this water bottle has multiple sealing interfaces that change depending on the valve / straw configuration. Perhaps a leak forms when the valve is at a specific angle, but not when the spout is fully closed or open.

Axially rotating clips about a part are also useful for inspecting an entire gasket to groove relationship.

HIGH RESOLUTION CT SLICE IMAGING

CT slice imaging can be measured in Volume Graphics or exported to .stl for use in other softwares for dimensional inspection in PolyWorks, or FEA in Ansys. Scrolling through the part allows us to quickly detect voids, measure wall thickness, locate gaps between materials, and characterize leak paths. pinches, or cracks.

CT Scanning & 3D Printing Jumping Spider

CT Scanning & 3D Printing Spiders

With our micro-focus CT scanning systems we are able to collect the incredible details of objects like this spider. Learn more about the capability on our CT Scanning Services page.

The final result of the scan is a high resolution, water tight STL which is perfect for 3D printing. What isn’t perfect for printing is the internal geometry – the spinnerets. To really do something exceptional we printed the spider clear in order to make the inside geometry visible.

Category: X-Ray & CT Scanning